Solar cell module and method of producing the same

Abstract

Disclosed is a solar cell module in which a reduction in the adhesive strength of the sealing resin used is suppressed even after use in a severe environment for a long period of time, in which corrosion of an electrode is prevented, and which has favorable flame resistance. The solar cell module uses, as the sealing resin, a blended polymer of a thermoplastic ester polyol polyurethane resin including an ester-based polyol unit and a thermoplastic ether polyol polyurethane resin including an ether-based polyol unit. The blending mass ratio of the thermoplastic ester polyol polyurethane resin to the thermoplastic ether polyol polyurethane resin in the blended polymer is 10:90 to 50:50. The thermoplastic ether polyol polyurethane resin includes a polyurethane resin A having flame resistance and a polyurethane resin B having lower flame resistance but higher adhesion properties than the polyurethane resin A.

1 . A solar cell module comprising a module substrate, a first sealing resin layer, a solar battery cell with a tab wire connected thereto, a second sealing resin layer, and a protective sheet that are stacked one on top of another, wherein
 the first sealing resin layer and/or the second sealing resin layer are/is formed of a blended polymer of a thermoplastic ester polyol polyurethane resin including an ester-based polyol unit and a thermoplastic ether polyol polyurethane resin including an ether-based polyol unit,   a blending mass ratio of the thermoplastic ester polyol polyurethane resin to the thermoplastic ether polyol polyurethane resin in the blended polymer is 10:90 to 50:50, and   the thermoplastic ether polyol polyurethane resin comprises a polyurethane resin A having flame resistance and a polyurethane resin B having lower flame resistance and higher adhesion properties than the polyurethane resin A.   
     
     
         2 . The solar cell module according to  claim 1 , wherein a blending mass ratio of the polyurethane resin A to the polyurethane resin B is 30:20 to 30:60. 
     
     
         3 . The solar cell module according to  claim 1 , wherein the polyurethane resin A includes a non-halogen-based flame retardant. 
     
     
         4 . The solar cell module according to  claim 1 , wherein the second sealing resin layer and the protective sheet are a protective layer-attached sealing resin sheet integrated in advance. 
     
     
         5 . The solar cell module according to  claim 1 , wherein the tab wire is connected to a surface electrode provided on a light-receiving surface of the solar battery cell with a conductive adhesive. 
     
     
         6 . A method of producing a solar cell module, the method comprising: placing a stacked body in a vacuum laminator, the stacked body being prepared by stacking a module substrate, a first sealing resin sheet, a solar battery cell with a tab wire connected or temporarily pasted thereto, a second sealing resin sheet, and a protective sheet; and subjecting the stacked body to vacuum lamination treatment to integrate the stacked body at a time, wherein
 a sealing resin sheet formed of a blended polymer of a thermoplastic ester polyol polyurethane resin including an ester-based polyol unit and a thermoplastic ether polyol polyurethane resin including an ether-based polyol unit is used as the first sealing resin sheet and/or the second sealing resin sheet, a blending mass ratio of the thermoplastic ester polyol polyurethane resin to the thermoplastic ether polyol polyurethane resin in the blended polymer is 10:90 to 50:50, and the thermoplastic ether polyol polyurethane resin includes a polyurethane resin A having flame resistance and a polyurethane resin B having lower flame resistance and higher adhesion properties than the polyurethane resin A.   
     
     
         7 . The production method according to  claim 6 , wherein a protective layer-attached sealing resin sheet previously integrally formed is used as the second sealing resin sheet and the protective sheet. 
     
     
         8 . A sealing resin sheet for a solar cell module, the sealing resin sheet formed of a blended polymer of a thermoplastic polyester polyol polyurethane resin including an ester-based polyol unit and a thermoplastic polyether polyol polyurethane resin including an ether-based polyol unit, wherein
 a blending mass ratio of the thermoplastic ester polyol polyurethane resin to the thermoplastic ether polyol polyurethane resin in the blended polymer is 10:90 to 50:50, and the thermoplastic ether polyol polyurethane resin includes a polyurethane resin A having flame resistance and a polyurethane resin B having lower flame resistance and higher adhesion properties than the polyurethane resin A.   
     
     
         9 . A protective layer-attached sealing resin sheet for a solar cell module, comprising a protective sheet and the sealing resin sheet for the solar cell module according to  claim 8 , the sealing resin sheet being stacked on the protective sheet. 
     
     
         10 . The solar cell module according to  claim 2 , wherein the polyurethane resin A includes a non-halogen-based flame retardant. 
     
     
         11 . The solar cell module according to  claim 2 , wherein the second sealing resin layer and the protective sheet are a protective layer-attached sealing resin sheet integrated in advance. 
     
     
         12 . The solar cell module according to  claim 3 , wherein the second sealing resin layer and the protective sheet are a protective layer-attached sealing resin sheet integrated in advance. 
     
     
         13 . The solar cell module according to  claim 10 , wherein the second sealing resin layer and the protective sheet are a protective layer-attached sealing resin sheet integrated in advance. 
     
     
         14 . The solar cell module according to  claim 2 , wherein the tab wire is connected to a surface electrode provided on a light-receiving surface of the solar battery cell with a conductive adhesive. 
     
     
         15 . The solar cell module according to  claim 3 , wherein the tab wire is connected to a surface electrode provided on a light-receiving surface of the solar battery cell with a conductive adhesive. 
     
     
         16 . The solar cell module according to  claim 10 , wherein the tab wire is connected to a surface electrode provided on a light-receiving surface of the solar battery cell with a conductive adhesive. 
     
     
         17 . The solar cell module according to  claim 4 , wherein the tab wire is connected to a surface electrode provided on a light-receiving surface of the solar battery cell with a conductive adhesive. 
     
     
         18 . The solar cell module according to  claim 11 , wherein the tab wire is connected to a surface electrode provided on a light-receiving surface of the solar battery cell with a conductive adhesive. 
     
     
         19 . The solar cell module according to  claim 12 , wherein the tab wire is connected to a surface electrode provided on a light-receiving surface of the solar battery cell with a conductive adhesive. 
     
     
         20 . The solar cell module according to  claim 13 , wherein the tab wire is connected to a surface electrode provided on a light-receiving surface of the solar battery cell with a conductive adhesive.